EP2463512B1 - Wind turbine tower assembly and method for assembling the same - Google Patents
Wind turbine tower assembly and method for assembling the same Download PDFInfo
- Publication number
- EP2463512B1 EP2463512B1 EP11190874.5A EP11190874A EP2463512B1 EP 2463512 B1 EP2463512 B1 EP 2463512B1 EP 11190874 A EP11190874 A EP 11190874A EP 2463512 B1 EP2463512 B1 EP 2463512B1
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- EP
- European Patent Office
- Prior art keywords
- legs
- base section
- wind turbine
- assembly
- turbine tower
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- 238000000034 method Methods 0.000 title description 25
- 230000015572 biosynthetic process Effects 0.000 claims description 10
- 230000013011 mating Effects 0.000 description 15
- 239000000463 material Substances 0.000 description 7
- 230000008878 coupling Effects 0.000 description 5
- 238000010168 coupling process Methods 0.000 description 5
- 238000005859 coupling reaction Methods 0.000 description 5
- 238000012423 maintenance Methods 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 229910000831 Steel Inorganic materials 0.000 description 4
- 239000010959 steel Substances 0.000 description 4
- 230000001154 acute effect Effects 0.000 description 3
- 238000009434 installation Methods 0.000 description 3
- 238000000429 assembly Methods 0.000 description 2
- 230000006870 function Effects 0.000 description 2
- 239000007769 metal material Substances 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 238000005728 strengthening Methods 0.000 description 2
- 238000005336 cracking Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 238000005457 optimization Methods 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
Images
Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
- E04H12/00—Towers; Masts or poles; Chimney stacks; Water-towers; Methods of erecting such structures
- E04H12/02—Structures made of specified materials
- E04H12/08—Structures made of specified materials of metal
- E04H12/085—Details of flanges for tubular masts
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
- E02D27/00—Foundations as substructures
- E02D27/32—Foundations for special purposes
- E02D27/42—Foundations for poles, masts or chimneys
-
- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
- E02D27/00—Foundations as substructures
- E02D27/32—Foundations for special purposes
- E02D27/42—Foundations for poles, masts or chimneys
- E02D27/425—Foundations for poles, masts or chimneys specially adapted for wind motors masts
-
- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
- E02D27/00—Foundations as substructures
- E02D27/32—Foundations for special purposes
- E02D27/52—Submerged foundations, i.e. submerged in open water
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
- F03D—WIND MOTORS
- F03D13/00—Assembly, mounting or commissioning of wind motors; Arrangements specially adapted for transporting wind motor components
- F03D13/20—Arrangements for mounting or supporting wind motors; Masts or towers for wind motors
- F03D13/22—Foundations specially adapted for wind motors
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02B—HYDRAULIC ENGINEERING
- E02B17/00—Artificial islands mounted on piles or like supports, e.g. platforms on raisable legs or offshore constructions; Construction methods therefor
- E02B2017/0091—Offshore structures for wind turbines
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
- E04H12/00—Towers; Masts or poles; Chimney stacks; Water-towers; Methods of erecting such structures
- E04H2012/006—Structures with truss-like sections combined with tubular-like sections
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
- F05B2240/00—Components
- F05B2240/90—Mounting on supporting structures or systems
- F05B2240/91—Mounting on supporting structures or systems on a stationary structure
- F05B2240/912—Mounting on supporting structures or systems on a stationary structure on a tower
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/70—Wind energy
- Y02E10/72—Wind turbines with rotation axis in wind direction
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/70—Wind energy
- Y02E10/728—Onshore wind turbines
Definitions
- the subject matter described herein relates generally to wind turbines and, more particularly, to a wind turbine tower assembly and a method for assembling the same.
- wind turbines include a tower and a rotor mounted on the tower via a nacelle.
- the rotor includes a number of blades that facilitate converting wind energy into rotational energy.
- the rotor drives a generator through a gearbox via a rotor shaft, and the gearbox steps up the inherently low rotational speed of the rotor shaft such that the generator can convert the mechanical energy to electrical energy. See, for example, EP 2 444 663 , US 2006/267348 and US 2009/031639 .
- Taller wind turbine towers have been known to facilitate generating greater Annual Energy Production (AEP) by enabling the rotor to capture more wind shear at higher altitudes.
- AEP Annual Energy Production
- these taller towers have also been known to experience increased loading.
- many taller towers have large, tubular bases configured to withstand the increased loading (e.g., tubular bases having thicker walls and/or a larger diameter), and these large, tubular bases have been known to render the tower more difficult and expensive to manufacture, transport, assemble, and maintain.
- Fig. 1 is a schematic representation of a wind turbine 100.
- wind turbine 100 is a horizontal axis wind turbine.
- wind turbine 100 may be a vertical axis wind turbine.
- Wind turbine 100 includes a tower 102 erected from a foundation 104 (e.g., a concrete foundation), a nacelle 106 mounted on tower 102, and a rotor 108 rotatably coupled to nacelle 106.
- Rotor 108 includes a plurality of blades 110.
- tower 102 includes a splayed base section 112 having a longitudinal axis L B , at least one tubular (e.g., cylindrical or conical) intermediate section 114 having a longitudinal axis L I , and a tubular (e.g., cylindrical or conical) top section 116 having a longitudinal axis L T such that base section 112, intermediate section(s) 114, and top section 116 are substantially coaxial with one another.
- tubular (e.g., cylindrical or conical) intermediate section 114 having a longitudinal axis L I
- tubular (e.g., cylindrical or conical) top section 116 having a longitudinal axis L T such that base section 112, intermediate section(s) 114, and top section 116 are substantially coaxial with one another.
- Base section 112 includes a plurality of legs 118 mounted on foundation 104 (e.g., partially embedded within a concrete foundation using dowel pins, bosses, or tenons for alignment) and arranged in a tripod formation such that legs 118 are obliquely oriented relative to longitudinal axis L B , as described in more detail below.
- base section 112 may have any suitable number of legs 118 arranged in any suitable formation that enables base section 112 to function as described herein.
- tower 102 may not have intermediate section(s) 114 (e.g., tower 102 may only have base section 112 and top section 116).
- intermediate section(s) 114 and/or top section 116 may not be tubular (e.g., intermediate section(s) 114 and/or top section 116 may also have a plurality of obliquely oriented legs, as described in more detail below).
- Fig. 2 is a perspective view of one of legs 118
- Fig. 3 is a side view of one of legs 118
- Fig. 4 is a side view of legs 118 nested together.
- each leg 118 has an upper flange 120, a lower flange 122, and a body 124 extending between upper flange 120 and lower flange 122.
- Body 124 having a length LL, is arcuately shaped to facilitate strengthening base section 112 and enabling legs 118 to be nested together for easier storage and/or transport of base section 112 (e.g., via rail or vessel).
- each body 124 has curvature equal to an angle of about 120° such that bodies 124 would form a completely tubular section (i.e., 360°) if aligned together along their lengths LL.
- body 124 may have any suitable shape that enables leg 118 to function as described herein (e.g., body 124 may be v-shaped, u-shaped, or w-shaped, rather than arcuately shaped).
- at least one support web may be mounted within body 124 and span the arcuate shape of body 124 to facilitate internally supporting body 124 (e.g., a plurality of support webs may be internally spaced along length LL of body 124 for added support).
- lower flange 122 has a mating surface 126 and a plurality of fastener apertures 128 (e.g., bolt holes). Lower flange 122 is coupled to and extends radially outward from body 124 such that mating surface 126 is oriented at an acute angle ⁇ relative to an imaginary lower end line IL LE that is substantially perpendicular to length LL of body 124.
- fastener apertures 128 e.g., bolt holes
- upper flange 120 has a top segment 130, a first side segment 132, and a second side segment 134 that are integrally formed (e.g., die cast) together, and each segment 130, 132, 134 has a mating surface 136, 138, 140, respectively, and a plurality of fastener apertures 142 (e.g., bolt holes).
- Side segments 132, 134 extend from opposing ends of top segment 130 such that mating surfaces 138, 140 are oriented relative to mating surface 136 at an angle ⁇ that is about 90°.
- upper flange 120 is coupled to body 124 such that top segment 130 extends radially outward from body 124 with mating surface 136 oriented at an acute angle ⁇ relative to an imaginary upper end line IL UE that is substantially perpendicular to length LL of body 124.
- Angle ⁇ and angle ⁇ are the same in the exemplary embodiment. However, angle ⁇ and angle ⁇ may be different in another embodiment.
- flanges 120, 122 may extend radially inward, rather than radially outward.
- body 124 and flanges 120, 122 may be fabricated from a metallic material and welded together (e.g., body 124 may be stamped from a single sheet of steel material, cut from a tube of steel material, or assembled from individually rolled segments of steel material that vary in thickness and are circumferentially welded together for stress optimization).
- body 124 and/or flanges 120, 122 may be fabricated from any suitable material, in any suitable manner, and in any suitable configuration (e.g., segments 130, 132, 134 of upper flange 120 may be formed separately from one another and coupled together rather than being integrally formed, or legs 118 may not be configured for nesting with one another).
- Figs. 5 and 6 are perspective and top views, respectively, of base section 112 in an assembled configuration.
- base section 112 has three legs 118 coupled together such that mating surface 138 of each leg 118 is fastened to mating surface 140 of an adjacent leg 118 via fasteners (e.g., bolts) inserted through at least some of fastener apertures 142. Because mating surfaces 138, 140 are oriented relative to mating surface 136 at angle ⁇ that is about 90°, legs 118 extend downward and outward in a tripod formation when upper flanges 120 are coupled together.
- fasteners e.g., bolts
- mating surfaces 126 of lower flanges 122 and mating surfaces 136 of upper flanges 120 are oriented at the same acute angles ⁇ and ⁇ , respectively, mating surfaces 126 can be seated on foundation 104 with mating surfaces 136 forming an interface (e.g., a generally annular interface) on a substantially common plane that is substantially perpendicular to longitudinal axis L B (i.e., legs 118 are obliquely oriented relative to longitudinal axis L B at the interface).
- an interface e.g., a generally annular interface
- an imaginary base circle C I can be drawn through midpoints M of arcuate bodies 124 near lower flanges 122 to define a footprint of base section 112, and the curvature of each body 124 proximate to lower flange 122 is greater than the curvature of imaginary base circle C I , which increases the structural integrity of base section 112.
- the interface formed by mating surfaces 136 may be any suitable shape.
- angle ⁇ , angle ⁇ , and/or the oblique angle of legs 118 relative to longitudinal axis L B may be selected in accordance with structural considerations of tower 102 such as, for example, the height of tower 102 and/or the environment in which wind turbine 100 is to be operated.
- legs 118 may be coupled together at any suitable location in other embodiments to facilitate strengthening base section 112 (e.g., legs 118 may be coupled together via cross-bracing member(s) 311 ( Fig. 9 ) positioned at any desired location on bodies 124, in addition to being coupled together at upper flanges 120).
- legs 118 may be coupled together in any suitable configuration and mounted on any suitable foundation in any suitable manner.
- a plurality of covers 144 are coupled to legs 118 to cover gaps 146 (shown in part via a cutout of cover 144 in Fig. 5 ) formed between adjacent legs 118 (e.g., the exemplary base section 112 has three triangularly shaped gaps 146 and three correspondingly shaped covers 144 for covering gaps 146).
- Covers 144 are removably coupled to legs 118 to facilitate opening and closing gaps 146 as desired, and covers 144 are not configured to strengthen base section 112 (i.e., covers 144 are configured for removal without jeopardizing the structural integrity of base section 112).
- At least one cover 144 has a door 148 (e.g., a door sized for walking therethrough or a door sized for driving a vehicle therethrough) that provides access into tower 102 (e.g., for maintenance) and/or a vent 150 that facilitates permitting airflow into and/or out of tower 102 (e.g., for releasing heat from within tower 102).
- Door 148 and/or vent 150 are located on cover(s) 144, rather than on legs 118, such that door 148 and/or vent 150 do not detract from the overall structural integrity of base section 112.
- covers 144 may alternatively be configured to contribute to the structural integrity of base section 112 in other embodiments, meaning that covers 144 may not be configured for removal after installation.
- door 148 and/or vent 150 may be located on legs 118, rather than covers 144, in some embodiments.
- base section 112 may not include covers 144 but, rather, may include an internal covering over the down-tower electrical equipment and/or other operational equipment.
- covers 144 may be fabricated from a fiberglass material, a fabric material, or a corrugated sheet metal material.
- covers 144 and gaps 146 may be any suitable size or shape, and covers 144 may have any suitable configuration.
- Fig. 7 is a perspective view of another base section 200 for use in wind turbine tower 102
- Fig. 8 is a top view of a leg 202 of base section 200.
- Base section 200 is similar to base section 112.
- base section 200 has a pair of legs 202 arranged in a bipod formation.
- Covers 210 similar to covers 144 of Figs. 5 and 6 , are coupled between legs 202.
- each leg 202 has an upper flange 204, a lower flange 206, and a body 208 extending between upper flange 204 and lower flange 206.
- Flanges 204, 206 are similar to flanges 120, 122 of Figs. 2-6 .
- upper flanges 204 extend radially inward from body 208
- upper flanges 204 may suitably extend radially outward from body 208 in other embodiments.
- bodies 208 are curved and flared near lower flanges 206 (e.g., legs 202 are wider and have less curvature near lower flanges 206) to increase the structural integrity of base section 200 (e.g., bodies 208, when coupled together, form a substantially elliptical shape near lower flanges 206 and a substantially circular shape near upper flanges 204 such that the spread of legs 202 is increased for added support).
- bodies 208 may have substantially the same semi-circular or semi-elliptical curvature near upper flange 204 and lower flange 206.
- legs 202 may have any desired curvature.
- Fig. 9 is a perspective view of another base section 300 for use in wind turbine 100.
- Base section 300 is similar to base section 112. However, base section 300 has a lower tier 302 and an upper tier 304 atop of lower tier 302.
- Lower tier 302 has three legs 306, and upper tier 304 has three legs 308.
- Legs 306, 308 are similar to legs 118 of Figs. 2-6 .
- Each leg 306 is mounted on an individual concrete pile 310 (e.g., via lower flanges 122 of legs 306) to facilitate reducing the risk of cracking that may be associated with a single, large concrete slab, and each leg 308 is coupled atop a respective one of legs 306.
- Legs 308 are coupled to one another in a manner similar to legs 118 of Figs. 2-6 (e.g., legs 308 may be coupled to one another at upper flanges 120 of legs 308, and legs 308 may be mounted on legs 306 by coupling lower flanges 122 of legs 308 to upper flanges 120 of legs 306 via bolts inserted through aligned fastener apertures 128, 142).
- lower tier 302 and upper tier 304 may have any suitable number of legs (e.g., base section 300 may not be arranged in a tripod formation).
- wind turbine 100 may be erected offshore, and concrete piles 310 may be at least partially submerged (e.g., built into the seabed) and configured at an angle relative to one another (e.g., each concrete pile 310 may be oriented at substantially the same angle as the leg 306 mounted thereon, with a bridging brace spanning base section 300 and connecting legs 306 together near the tops of piles 310).
- base section 300 may have any suitable number of tiers (e.g., base section 300 may have a lower tier, at least one intermediate tier, and an upper tier that each has a plurality of legs).
- a platform 312 is coupled between lower tier 302 and upper tier 304 to facilitate reinforcing base section 300 and to facilitate providing a surface upon which to perform maintenance on tower 102.
- Platform 312 has three segments 314 that are detachably coupled together via any suitable coupling device (e.g., a lap joint).
- each segment 314 may be coupled to a respective one of lower legs 306 prior to each lower leg 306 being mounted on one of concrete piles 310, prior to segments 314 being coupled together, and prior to assembling upper tier 304 on lower tier 302.
- lower legs 306 may first be mounted on concrete piles 310, and platform 312 may then be mounted onto lower legs 306 (e.g., via a crane) after segments 314 have already been coupled together and prior to assembling upper tier 304 on lower tier 302.
- Alternative methods of assembly may also be used.
- platform 312 facilitates easier storage and/or transport of platform 312 (e.g., platform 312 may be stored and/or transported in a disassembled condition and assembled on site).
- base section 300 may have any suitable number of platforms 312, and platforms 312 may be mounted at any suitable location.
- platform 312 may have any suitable number of segments 314 arranged in any suitable manner.
- any suitable cross-bracing member(s) 311 may be used in lieu of, or in combination with, platform 312 (e.g., as shown in Fig.
- cross-bracing member(s) 311 may be bolted between legs 306 and/or 308 and may be fabricated in a channel or C-beam configuration using steel, or cross-bracing members 311 may be arranged in a lattice formation between legs 306 and/or 308 in other embodiments). Additionally, covers similar to covers 144 of Figs. 5 and 6 may be coupled to lower legs 306 and/or upper legs 308 to cover gaps as desired. It should also be recognized that, while individual concrete piles 310, cross-bracing members 311, and platform(s) 312 are described herein as being useful in this tiered base section 300, similar concrete piles 310 and/or platform(s) 312 may also be used with the other embodiments described herein.
- Fig. 10 is a flow chart of a method 400 for assembling a wind turbine tower.
- Method 400 includes providing 402 a tubular section having a first longitudinal axis and providing 404 a base section having a plurality of legs coupled together at an interface such that the base section has a second longitudinal axis, wherein the legs are obliquely oriented relative to the second longitudinal axis at the interface.
- Method 400 further includes coupling 406 the tubular section to the base section at the interface such that the base section and the tubular section are in substantially coaxial alignment and such that the tubular section is supported on the legs.
- method 400 may also include arranging the legs in a tripod formation. In another embodiment, method 400 may include arranging the legs in a bipod formation. In some embodiments, method 400 may include embedding each of the legs in an individual concrete pile. In other embodiments, method 400 may include coupling a removable cover over a gap between a pair of the legs. In one alternative embodiment, method 400 may include assembling a first tier of the base section using the legs, assembling a second tier of the base section on the first tier using the legs, and mounting a platform between the first tier and the second tier. In another alternative embodiment, method 400 may include coupling a plurality of platform segments together to form the platform.
- the methods and systems described herein facilitate providing a wind turbine tower having a base section that is configured to withstand the increased loading associated with larger towers.
- the methods and systems described herein also facilitate providing a wind turbine tower having a base section with legs that can be more easily and cheaply packaged and/or transported to the site at which the tower is to be erected (e.g., each individual leg or each set of nested legs can fit into a 4.3m by 4.3m shipping envelope, thereby reducing a cost associated with transporting the base section).
- the methods and systems described herein further facilitate providing a wind turbine tower having a base section that can be manufactured using less material, thereby decreasing a manufacturing cost associated with fabricating the tower.
- the methods and systems described herein facilitate providing a wind turbine tower with a base section that enables down-tower electronic equipment, as well as other operational equipment, to be more completely assembled outside of the base section and moved into the base section after the base section has been installed, in addition to facilitating removal of the equipment from the base section in larger sub-assemblies for maintenance, with less disassembly of the equipment having to occur within the base section, thereby reducing time and costs associated with assembling and maintaining the wind turbine.
- the methods and systems described herein facilitate reducing costs associated with manufacturing, assembling, transporting, and/or maintaining a wind turbine.
- Exemplary embodiments of a wind turbine tower assembly and a method for assembling the same are described above in detail.
- the methods and systems described herein are not limited to the specific embodiments described herein, but, rather, components of the systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein.
- the methods and systems described herein may have other applications not limited to practice with wind turbines, as described herein. Rather, the methods and systems described herein can be implemented and utilized in connection with various other industries.
Description
- The subject matter described herein relates generally to wind turbines and, more particularly, to a wind turbine tower assembly and a method for assembling the same.
- Many known wind turbines include a tower and a rotor mounted on the tower via a nacelle. The rotor includes a number of blades that facilitate converting wind energy into rotational energy. The rotor drives a generator through a gearbox via a rotor shaft, and the gearbox steps up the inherently low rotational speed of the rotor shaft such that the generator can convert the mechanical energy to electrical energy. See, for example,
EP 2 444 663 ,US 2006/267348 andUS 2009/031639 . - Taller wind turbine towers have been known to facilitate generating greater Annual Energy Production (AEP) by enabling the rotor to capture more wind shear at higher altitudes. However, these taller towers have also been known to experience increased loading. As such, many taller towers have large, tubular bases configured to withstand the increased loading (e.g., tubular bases having thicker walls and/or a larger diameter), and these large, tubular bases have been known to render the tower more difficult and expensive to manufacture, transport, assemble, and maintain. As such, it would be useful to provide a wind turbine tower with a base that is configured to withstand the increased loading of taller towers, while reducing a cost associated with manufacturing, transporting, assembling, and/or maintaining the tower.
- Therefore, the present invention, as defined by the appended claims, is provided.
- Various aspects and embodiments of the present invention will now be described in connection with the accompanying drawings, in which:
-
Fig. 1 is a schematic representation of an exemplary wind turbine; -
Fig. 2 is a perspective view of a leg of a base section of the wind turbine shown inFig. 1 ; -
Fig. 3 is a side view of the leg shown inFig. 2 ; -
Fig. 4 is a side view of the leg shown inFig. 2 nested with other legs of the base section of the wind turbine shown inFig. 1 ; -
Fig. 5 is a perspective view of the base section of the wind turbine shown inFig. 1 ; -
Fig. 6 is a top view of the base section shown inFig. 5 ; -
Fig. 7 is a perspective view of another base section for use in the wind turbine shown inFig. 1 ; -
Fig. 8 is a top view of a leg of the base section shown inFig. 7 ; -
Fig. 9 is a perspective view of another base section for use in the wind turbine shown inFig. 1 ; and -
Fig. 10 is a flow chart of a method for assembling a tower of the wind turbine shown inFig. 1 . - The following detailed description describes a wind turbine tower assembly and a method for assembling the same by way of example and not by way of limitation. The description enables one of ordinary skill in the art to make and use the disclosure, and the description describes several embodiments of the disclosure, including what is presently believed to be the best mode of carrying out the disclosure. The disclosure is described herein as being applied to an exemplary embodiment, namely, a wind turbine tower. However, it is contemplated that this disclosure has general application to towers in a broad range of systems and in a variety of applications other than wind turbines.
-
Fig. 1 is a schematic representation of awind turbine 100. In the exemplary embodiment,wind turbine 100 is a horizontal axis wind turbine. In other embodiments,wind turbine 100 may be a vertical axis wind turbine.Wind turbine 100 includes atower 102 erected from a foundation 104 (e.g., a concrete foundation), anacelle 106 mounted ontower 102, and arotor 108 rotatably coupled tonacelle 106.Rotor 108 includes a plurality ofblades 110. - In the exemplary embodiment,
tower 102 includes a splayedbase section 112 having a longitudinal axis LB, at least one tubular (e.g., cylindrical or conical)intermediate section 114 having a longitudinal axis LI, and a tubular (e.g., cylindrical or conical)top section 116 having a longitudinal axis LT such thatbase section 112, intermediate section(s) 114, andtop section 116 are substantially coaxial with one another.Base section 112 includes a plurality oflegs 118 mounted on foundation 104 (e.g., partially embedded within a concrete foundation using dowel pins, bosses, or tenons for alignment) and arranged in a tripod formation such thatlegs 118 are obliquely oriented relative to longitudinal axis LB, as described in more detail below. In some embodiments,base section 112 may have any suitable number oflegs 118 arranged in any suitable formation that enablesbase section 112 to function as described herein. In other embodiments,tower 102 may not have intermediate section(s) 114 (e.g.,tower 102 may only havebase section 112 and top section 116). Alternatively, intermediate section(s) 114 and/ortop section 116 may not be tubular (e.g., intermediate section(s) 114 and/ortop section 116 may also have a plurality of obliquely oriented legs, as described in more detail below). -
Fig. 2 is a perspective view of one oflegs 118, andFig. 3 is a side view of one oflegs 118.Fig. 4 is a side view oflegs 118 nested together. In the exemplary embodiment, eachleg 118 has anupper flange 120, alower flange 122, and abody 124 extending betweenupper flange 120 andlower flange 122.Body 124, having a length LL, is arcuately shaped to facilitate strengtheningbase section 112 and enablinglegs 118 to be nested together for easier storage and/or transport of base section 112 (e.g., via rail or vessel). In some embodiments, eachbody 124 has curvature equal to an angle of about 120° such thatbodies 124 would form a completely tubular section (i.e., 360°) if aligned together along their lengths LL. In other embodiments,body 124 may have any suitable shape that enablesleg 118 to function as described herein (e.g.,body 124 may be v-shaped, u-shaped, or w-shaped, rather than arcuately shaped). In some embodiments, at least one support web may be mounted withinbody 124 and span the arcuate shape ofbody 124 to facilitate internally supporting body 124 (e.g., a plurality of support webs may be internally spaced along length LL ofbody 124 for added support). - In the exemplary embodiment,
lower flange 122 has amating surface 126 and a plurality of fastener apertures 128 (e.g., bolt holes).Lower flange 122 is coupled to and extends radially outward frombody 124 such thatmating surface 126 is oriented at an acute angle α relative to an imaginary lower end line ILLE that is substantially perpendicular to length LL ofbody 124. In the exemplary embodiment,upper flange 120 has atop segment 130, afirst side segment 132, and asecond side segment 134 that are integrally formed (e.g., die cast) together, and eachsegment mating surface Side segments top segment 130 such thatmating surfaces mating surface 136 at an angle θ that is about 90°. Additionally,upper flange 120 is coupled tobody 124 such thattop segment 130 extends radially outward frombody 124 withmating surface 136 oriented at an acute angle β relative to an imaginary upper end line ILUE that is substantially perpendicular to length LL ofbody 124. Angle α and angle β are the same in the exemplary embodiment. However, angle α and angle β may be different in another embodiment. - In some embodiments,
flanges body 124 andflanges body 124 may be stamped from a single sheet of steel material, cut from a tube of steel material, or assembled from individually rolled segments of steel material that vary in thickness and are circumferentially welded together for stress optimization). Alternatively,body 124 and/orflanges segments upper flange 120 may be formed separately from one another and coupled together rather than being integrally formed, orlegs 118 may not be configured for nesting with one another). -
Figs. 5 and6 are perspective and top views, respectively, ofbase section 112 in an assembled configuration. In the exemplary embodiment,base section 112 has threelegs 118 coupled together such thatmating surface 138 of eachleg 118 is fastened tomating surface 140 of anadjacent leg 118 via fasteners (e.g., bolts) inserted through at least some offastener apertures 142. Becausemating surfaces mating surface 136 at angle θ that is about 90°,legs 118 extend downward and outward in a tripod formation whenupper flanges 120 are coupled together. Also, becausemating surfaces 126 oflower flanges 122 andmating surfaces 136 ofupper flanges 120 are oriented at the same acute angles α and β, respectively,mating surfaces 126 can be seated onfoundation 104 withmating surfaces 136 forming an interface (e.g., a generally annular interface) on a substantially common plane that is substantially perpendicular to longitudinal axis LB (i.e.,legs 118 are obliquely oriented relative to longitudinal axis LB at the interface). Thus, an imaginary base circle CI can be drawn through midpoints M ofarcuate bodies 124 nearlower flanges 122 to define a footprint ofbase section 112, and the curvature of eachbody 124 proximate tolower flange 122 is greater than the curvature of imaginary base circle CI, which increases the structural integrity ofbase section 112. In other embodiments, the interface formed bymating surfaces 136 may be any suitable shape. - In some embodiments, angle α, angle β, and/or the oblique angle of
legs 118 relative to longitudinal axis LB may be selected in accordance with structural considerations oftower 102 such as, for example, the height oftower 102 and/or the environment in whichwind turbine 100 is to be operated. Additionally, whilelegs 118 are not coupled together other than atupper flanges 120 in the exemplary embodiment,legs 118 may be coupled together at any suitable location in other embodiments to facilitate strengthening base section 112 (e.g.,legs 118 may be coupled together via cross-bracing member(s) 311 (Fig. 9 ) positioned at any desired location onbodies 124, in addition to being coupled together at upper flanges 120). Alternatively,legs 118 may be coupled together in any suitable configuration and mounted on any suitable foundation in any suitable manner. - In the exemplary embodiment, a plurality of
covers 144 are coupled tolegs 118 to cover gaps 146 (shown in part via a cutout ofcover 144 inFig. 5 ) formed between adjacent legs 118 (e.g., theexemplary base section 112 has three triangularlyshaped gaps 146 and three correspondinglyshaped covers 144 for covering gaps 146).Covers 144 are removably coupled tolegs 118 to facilitate opening andclosing gaps 146 as desired, andcovers 144 are not configured to strengthen base section 112 (i.e.,covers 144 are configured for removal without jeopardizing the structural integrity of base section 112). Additionally, at least onecover 144 has a door 148 (e.g., a door sized for walking therethrough or a door sized for driving a vehicle therethrough) that provides access into tower 102 (e.g., for maintenance) and/or avent 150 that facilitates permitting airflow into and/or out of tower 102 (e.g., for releasing heat from within tower 102).Door 148 and/orvent 150 are located on cover(s) 144, rather than onlegs 118, such thatdoor 148 and/orvent 150 do not detract from the overall structural integrity ofbase section 112. However, covers 144 may alternatively be configured to contribute to the structural integrity ofbase section 112 in other embodiments, meaning that covers 144 may not be configured for removal after installation. Additionally,door 148 and/or vent 150 may be located onlegs 118, rather thancovers 144, in some embodiments. - Because
gaps 146 betweenadjacent legs 118 are large and becausecovers 144 are removable, operational equipment ofwind turbine 100 may be more completely assembled outside oftower 102 and moved intotower 102 throughgaps 146 aftertower 102 has been at least partially erected and when one ofcovers 144 is removed, thereby enabling easier installation and maintenance of the operational equipment (e.g., the "down-tower" electrical equipment may be more completely assembled outside ofbase section 112 and driven through one ofgaps 146 on a truck for installation inbase section 112, in addition to the down-tower electrical equipment being removable frombase section 112 in larger sub-assemblies for maintenance outside of base section 112). In another embodiment,base section 112 may not includecovers 144 but, rather, may include an internal covering over the down-tower electrical equipment and/or other operational equipment. In some embodiments, covers 144 may be fabricated from a fiberglass material, a fabric material, or a corrugated sheet metal material. In other embodiments, covers 144 andgaps 146 may be any suitable size or shape, and covers 144 may have any suitable configuration. -
Fig. 7 is a perspective view of anotherbase section 200 for use inwind turbine tower 102, andFig. 8 is a top view of aleg 202 ofbase section 200.Base section 200 is similar tobase section 112. However,base section 200 has a pair oflegs 202 arranged in a bipod formation.Covers 210, similar tocovers 144 ofFigs. 5 and6 , are coupled betweenlegs 202. In this embodiment, eachleg 202 has anupper flange 204, alower flange 206, and abody 208 extending betweenupper flange 204 andlower flange 206.Flanges flanges Figs. 2-6 . Whileupper flanges 204 extend radially inward frombody 208,upper flanges 204 may suitably extend radially outward frombody 208 in other embodiments. In this embodiment,bodies 208 are curved and flared near lower flanges 206 (e.g.,legs 202 are wider and have less curvature near lower flanges 206) to increase the structural integrity of base section 200 (e.g.,bodies 208, when coupled together, form a substantially elliptical shape nearlower flanges 206 and a substantially circular shape nearupper flanges 204 such that the spread oflegs 202 is increased for added support). In other embodiments,bodies 208 may have substantially the same semi-circular or semi-elliptical curvature nearupper flange 204 andlower flange 206. Alternatively,legs 202 may have any desired curvature. -
Fig. 9 is a perspective view of anotherbase section 300 for use inwind turbine 100.Base section 300 is similar tobase section 112. However,base section 300 has alower tier 302 and anupper tier 304 atop oflower tier 302.Lower tier 302 has threelegs 306, andupper tier 304 has threelegs 308.Legs legs 118 ofFigs. 2-6 . Eachleg 306 is mounted on an individual concrete pile 310 (e.g., vialower flanges 122 of legs 306) to facilitate reducing the risk of cracking that may be associated with a single, large concrete slab, and eachleg 308 is coupled atop a respective one oflegs 306.Legs 308 are coupled to one another in a manner similar tolegs 118 ofFigs. 2-6 (e.g.,legs 308 may be coupled to one another atupper flanges 120 oflegs 308, andlegs 308 may be mounted onlegs 306 by couplinglower flanges 122 oflegs 308 toupper flanges 120 oflegs 306 via bolts inserted through alignedfastener apertures 128, 142). In some embodiments,lower tier 302 andupper tier 304 may have any suitable number of legs (e.g.,base section 300 may not be arranged in a tripod formation). In other embodiments,wind turbine 100 may be erected offshore, andconcrete piles 310 may be at least partially submerged (e.g., built into the seabed) and configured at an angle relative to one another (e.g., eachconcrete pile 310 may be oriented at substantially the same angle as theleg 306 mounted thereon, with a bridging brace spanningbase section 300 and connectinglegs 306 together near the tops of piles 310). Alternatively,base section 300 may have any suitable number of tiers (e.g.,base section 300 may have a lower tier, at least one intermediate tier, and an upper tier that each has a plurality of legs). - In this embodiment, a
platform 312 is coupled betweenlower tier 302 andupper tier 304 to facilitate reinforcingbase section 300 and to facilitate providing a surface upon which to perform maintenance ontower 102.Platform 312 has threesegments 314 that are detachably coupled together via any suitable coupling device (e.g., a lap joint). In one embodiment, eachsegment 314 may be coupled to a respective one oflower legs 306 prior to eachlower leg 306 being mounted on one ofconcrete piles 310, prior tosegments 314 being coupled together, and prior to assemblingupper tier 304 onlower tier 302. In another embodiment,lower legs 306 may first be mounted onconcrete piles 310, andplatform 312 may then be mounted onto lower legs 306 (e.g., via a crane) aftersegments 314 have already been coupled together and prior to assemblingupper tier 304 onlower tier 302. Alternative methods of assembly may also be used. - This segmented configuration facilitates easier storage and/or transport of platform 312 (e.g.,
platform 312 may be stored and/or transported in a disassembled condition and assembled on site). In some embodiments,base section 300 may have any suitable number ofplatforms 312, andplatforms 312 may be mounted at any suitable location. In other embodiments,platform 312 may have any suitable number ofsegments 314 arranged in any suitable manner. Alternatively, any suitable cross-bracing member(s) 311 may be used in lieu of, or in combination with, platform 312 (e.g., as shown inFig. 9 , cross-bracing member(s) 311 may be bolted betweenlegs 306 and/or 308 and may be fabricated in a channel or C-beam configuration using steel, orcross-bracing members 311 may be arranged in a lattice formation betweenlegs 306 and/or 308 in other embodiments). Additionally, covers similar tocovers 144 ofFigs. 5 and6 may be coupled tolower legs 306 and/orupper legs 308 to cover gaps as desired. It should also be recognized that, while individualconcrete piles 310,cross-bracing members 311, and platform(s) 312 are described herein as being useful in thistiered base section 300, similarconcrete piles 310 and/or platform(s) 312 may also be used with the other embodiments described herein. -
Fig. 10 is a flow chart of amethod 400 for assembling a wind turbine tower.Method 400 includes providing 402 a tubular section having a first longitudinal axis and providing 404 a base section having a plurality of legs coupled together at an interface such that the base section has a second longitudinal axis, wherein the legs are obliquely oriented relative to the second longitudinal axis at the interface.Method 400 further includescoupling 406 the tubular section to the base section at the interface such that the base section and the tubular section are in substantially coaxial alignment and such that the tubular section is supported on the legs. - In one embodiment,
method 400 may also include arranging the legs in a tripod formation. In another embodiment,method 400 may include arranging the legs in a bipod formation. In some embodiments,method 400 may include embedding each of the legs in an individual concrete pile. In other embodiments,method 400 may include coupling a removable cover over a gap between a pair of the legs. In one alternative embodiment,method 400 may include assembling a first tier of the base section using the legs, assembling a second tier of the base section on the first tier using the legs, and mounting a platform between the first tier and the second tier. In another alternative embodiment,method 400 may include coupling a plurality of platform segments together to form the platform. - The methods and systems described herein facilitate providing a wind turbine tower having a base section that is configured to withstand the increased loading associated with larger towers. The methods and systems described herein also facilitate providing a wind turbine tower having a base section with legs that can be more easily and cheaply packaged and/or transported to the site at which the tower is to be erected (e.g., each individual leg or each set of nested legs can fit into a 4.3m by 4.3m shipping envelope, thereby reducing a cost associated with transporting the base section). The methods and systems described herein further facilitate providing a wind turbine tower having a base section that can be manufactured using less material, thereby decreasing a manufacturing cost associated with fabricating the tower. Additionally, the methods and systems described herein facilitate providing a wind turbine tower with a base section that enables down-tower electronic equipment, as well as other operational equipment, to be more completely assembled outside of the base section and moved into the base section after the base section has been installed, in addition to facilitating removal of the equipment from the base section in larger sub-assemblies for maintenance, with less disassembly of the equipment having to occur within the base section, thereby reducing time and costs associated with assembling and maintaining the wind turbine. Thus, the methods and systems described herein facilitate reducing costs associated with manufacturing, assembling, transporting, and/or maintaining a wind turbine.
- Exemplary embodiments of a wind turbine tower assembly and a method for assembling the same are described above in detail. The methods and systems described herein are not limited to the specific embodiments described herein, but, rather, components of the systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, the methods and systems described herein may have other applications not limited to practice with wind turbines, as described herein. Rather, the methods and systems described herein can be implemented and utilized in connection with various other industries.
- This written description uses examples to disclose the invention, including the preferred mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
Claims (9)
- A wind turbine tower assembly (100), comprising:a tubular section (114) having a first longitudinal axis (Li); anda base section assembly (112) comprising a plurality of legs (118), said base section assembly (112) configured to be assembled into a base section having said legs coupled together at an interface wherein the base section has a second longitudinal axis (LB), and wherein said legs (118) are obliquely oriented relative to the second longitudinal axis (LB) at the interface, wherein the base section (112) is configured to support said tubular section (114) on said legs (118) and in substantially coaxial alignment with the base section; characterized in that:
each of said legs (118) comprises an upper flange (120), a lower flange (122), and an arcuately shaped body (124) extending between said upper flange and said lower flange. - A wind turbine tower assembly (100) in accordance with claim 1, wherein said legs (118) comprise three legs configured to be arranged in a tripod formation.
- A wind turbine tower assembly (100) in accordance with any preceding claim, wherein said legs (118) comprise two legs configured to be arranged in a bipod formation.
- A wind turbine tower assembly (100) in accordance with any preceding claim, wherein said legs (118) are configured to be nested together.
- A wind turbine tower assembly (100) in accordance with any preceding claim, wherein said base section assembly (112) further comprises a cover (144,210) configured to be removably coupled over a gap (146) between a pair of said legs (118).
- A wind turbine tower assembly (100) in accordance with claim 5, wherein said cover (144,210) comprises at least one of a drive-through door (148) and a vent (150).
- A wind turbine tower assembly (100) in accordance with any preceding claim, wherein said legs (118) comprise:a plurality of lower legs (306) configured for a lower tier (302) of the base section (300); anda plurality of upper legs (308) configured for an upper tier of the base section (304), said base section assembly further comprising at least one cross-bracing member (311) and a platform assembly configured to be assembled into a platform for mounting between said upper legs and said lower legs.
- A wind turbine tower assembly (100) in accordance with any preceding claim, wherein said platform assembly comprises a plurality of platform segments configured to be detachably coupled together.
- A base section assembly (112) for a wind turbine tower (102) having a tubular section (114) with a first longitudinal axis (Li), said base section (112) assembly comprising:
a plurality of legs (118), said base section assembly (112) configured to be assembled into a base section having said legs (118) coupled together at an interface, wherein the base section has a second longitudinal axis (LB) and wherein said legs (118) are obliquely oriented relative to the second longitudinal axis (LB) at the interface, wherein the base section is configured to support the tubular section (114) on said legs (118) and in substantially coaxial alignment with the base section, characterized in that:
each of said legs (118) comprises an upper flange (120), a lower flange (122), and an arcuately shaped body (124) extending between said upper flange and said lower flange.
Applications Claiming Priority (1)
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US12/962,381 US8544214B2 (en) | 2010-12-07 | 2010-12-07 | Wind turbine tower assembly and method for assembling the same |
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EP2463512A2 EP2463512A2 (en) | 2012-06-13 |
EP2463512A3 EP2463512A3 (en) | 2017-06-07 |
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US (1) | US8544214B2 (en) |
EP (1) | EP2463512B1 (en) |
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CA (1) | CA2759979C (en) |
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Also Published As
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CN102562490A (en) | 2012-07-11 |
CA2759979A1 (en) | 2012-06-07 |
US8544214B2 (en) | 2013-10-01 |
EP2463512A2 (en) | 2012-06-13 |
AU2011253836A1 (en) | 2012-06-21 |
AU2011253836B2 (en) | 2016-06-09 |
CA2759979C (en) | 2018-10-09 |
EP2463512A3 (en) | 2017-06-07 |
CN102562490B (en) | 2016-08-03 |
US20110138721A1 (en) | 2011-06-16 |
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